Double ended connector / utility unit

ABSTRACT

The present invention relates to a device for connecting insulation panels of insulated concrete formwork. Each panel has opposing edges and male interconnecting means on a first edge and female interconnecting means on a second edge. The device is a block with opposing edges wherein each opposing edge of the block has similar interconnecting means that mate with the interconnecting means on one of the edges of each of the panels.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119 to Canadian PatentApplication No. 2,574,694 entitled “DOUBLE ENDED CONNECTOR/UTILITY UNIT”filed Jan. 19, 2007, the contents of which are hereby incorporated byreference.

FIELD OF INVENTION

The present invention relates to a device intended for use with allinsulated concrete formwork (ICF) systems.

BACKGROUND OF INVENTION

Insulated concrete formwork is a well known system used for settingconcrete foundations. Typically, such formwork incorporates a series ofinsulation panels joined by a series of webs. The top and bottomsurfaces of the insulation panels typically have interconnecting meansto join the panels to other panels situated above or below. For manytypes of insulation panels, the top surfaces will have one type ofinterconnecting means, such as male interconnecting means. The bottomsurface of each panel will have an interconnecting means that connectsto the interconnecting means from the top surface. Where the top surfaceof each panel has male interconnecting means, the bottom surface ofother panels will have female interconnecting means for receiving themale interconnecting means.

As such, ideally the nature of the interconnecting means on the upperand lower surfaces of the formwork matches the interconnecting means onthe formwork of each individual ICF manufacturer. That is, separatedevices must be manufactured to be compatible with the ICF of eachproducer. The ICF geometries typically comprise a male connector on theupper surface and a female connector on the lower surface and canconsist of one or more rows of circular, rectangular or slotted shapesof matching male and female features.

Where two insulation panels each have a female interconnecting bottomedge and a male interconnecting top edge, the panels can only beconnected in a unidirectional fashion. In cases where an obstructionsuch as a gable, a door frame or a window frame is encountered duringthe construction of insulated concrete formwork and one or more panelsmust be cut so that a portion of the panel fits against the obstruction,the off cut is typically disposed of because either the femaleinterconnecting bottom edge or the male interconnecting top edge hasbeen cut away. It would be desirable to use the portions of those cutpanels rather than disposing of them. This could be achieved if theremaining portion of the panel could be inverted and attached to anotherpanel.

The present invention also can be used to utilize existing formwork withnon uniform width developed to provide support for brick veneer on oneor both faces of a wall. By inverting such formwork at the base of thewall such that a wider portion engages the ground, the greater widthprovided supports the bearing of the wall on the ground. This couldeliminate the cost and time expended to prepare a separate concretefooting in advance of assembling a wall of insulated concrete formwork.Use of the present invention on the upper narrower end of the invertedledger unit enables the next course of ICF to be placed with the topside uppermost, thus allowing the wall to be finished with conventionalICF panels.

A further application of the present invention is demonstrated when aconcrete wall is poured. When pouring concrete into the assembled ICFunits, it is very difficult to avoid fouling of the upper side of theICF unit with concrete. Cleaning the interconnecting means along thisupper surface is a very time consuming but necessary to achieveinterlocking when the next course of ICF units are placed for upwardcontinuation of the wall construction. The unit described herein can bepositioned temporarily along the top of the wall to protect the formworkon the upper side of the wall. After pouring the concrete, the unit canbe removed for reuse and construction of additional wall height can becontinued without delay.

Finally, the present invention can also be used to further stabilizeinsulated concrete formwork systems. More particularly, two like unitshaving male or female interconnecting means may be connected together bya stabilizing means such as a web. This application is particularlyuseful where the units have greater heights such that the outwardpressure of the greater mass of concrete between the units is moresignificant.

The desire to attach like surfaces of insulation panels is reflected inthe prior art. The prior art discloses panels with reversible connectingmeans. For example, U.S. Pat. No. 5,428,933 (Philippe) discloses aninsulating construction member with a top and bottom surface each havingalternating projections and recesses as interconnecting members. Thealternating interconnecting means on the top and bottom surfaces arearranged symmetrically so that they may be interconnected with a likemember in a bi-directional and/or reversible manner.

An insulating foam panel having alternating projections and recesses onits top and bottom surfaces is also disclosed in U.S. Pat. No. 6,401,419(Beliveau). The alternating projections and recesses permit theattachment of the top side and/or bottom side of a panel with either thetop side or the bottom side of a like panel.

U.S. Pat. No. 6,820,384 (Pfeiffer) discloses insulation panels withalternating teeth and sockets along opposing edges of each panel. Thus,each panel may engage either opposing vertical end of a horizontallyadjacent block panel.

The prior art reversible systems each disclose panels with alternatingmale and female interconnecting means. However, insulated concrete formsystems incorporating panels with only male interconnecting means orfemale interconnecting means: on their top and bottom surfaces are stillin use. There is a need for a means for making such systems reversible.

SUMMARY OF INVENTION

The invention here comprises a device of connecting insulation panels ofinsulated concrete formwork. Each insulation panel has opposing edgesand male interconnecting means on a first edge and femaleinterconnecting means on a second edge. The devices includes a blockwith opposing edges wherein each opposing edge of the block has onlymale interconnecting means and said male interconnecting means can matewith said female interconnecting means on said second edge of each ofsaid panels.

A further embodiment of the invention comprises a device for connectinginsulation panels of insulated concrete formwork. Each insulation panelhas opposing edges and male interconnecting means on a first edge andfemale interconnecting means on a second edge. The device includes ablock with opposing edges wherein each opposing edge of the block hasonly female interconnecting means and said female interconnecting meanscan mate with said male interconnecting means on said first edge of eachof said panels.

A further embodiment of the invention comprises a system for insulatingconcrete formwork. The system includes a plurality of insulation panelswherein each panel has opposing edges and male interconnecting means ona first said edge and female interconnecting means on a second saidedge. The system further comprises at least one block connecting two ofsaid insulation panels wherein each opposing edge of said block has onlymale interconnecting means that can mate with said femaleinterconnecting on said second edge of each of said panels.

A further embodiment of the invention comprises a system for insulatingconcrete formwork. The system includes a plurality of insulation panelswherein each panel has opposing edges and male interconnecting means ona first said edge and female interconnecting means on a second saidedge. The system also includes at least one block connecting two of saidinsulation panels wherein each opposing edge of said block has onlyfemale interconnecting means that can mate with said maleinterconnecting means on said first edge of each of said panels.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate by way of example only preferredembodiments of the invention:

FIG. 1 is a perspective view of an insulation panel that has beensevered into two portions;

FIG. 2A is an exploded perspective view of the portions of theinsulation panel from FIG. 1 and a double ended connector with femaleinterconnecting means;

FIG. 2B is an exploded perspective view of the portions of theinsulation panel from FIG. 1 and a double ended connector with maleinterconnecting means;

FIG. 3 is a perspective view of insulated concrete formworkincorporating two double ended connectors.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An insulation panel 10 is shown in FIG. 1. The insulation panel 10 isformed from a malleable substance such as polystyrene or the like. Theinsulation panel 10 has a bottom edge 14 and a top edge 18 which opposesthe bottom edge 14. The bottom edge 14 and the top edge 18 each havemeans for connecting the insulation panel 10 to other insulation panels.

The top edge 18 of the insulation panel 10 shown in FIG. 1 has a seriesof male interconnecting means 22. The male interconnecting means 22include projections 26 and bridges 30. It will be apparent to a personskilled in the art that the male interconnecting means may have variableshapes and sizes and may or may not include bridges or portionsconnecting the projections. The bridges 30 each connect adjacentprojections 26.

The bottom edge 14 of the insulation panel 10 has a series of femaleinterconnecting means 34. The female interconnecting means 34 includerecesses 38 and grooves 42. It will be apparent to a person skilled inthe art that the female interconnecting means may have variable shapesand sizes and may or may not include grooves or portions connecting therecesses. It will also be apparent to a person skilled in the art thatthe female interconnecting means are of a shape and size to receive thevariably shaped and sized male interconnecting means. The recesses 38and the grooves 42 are each defined by the insulation panel 10. Thegrooves 42 each connect adjacent recesses 38. The female interconnectingmeans 34 are sized to receive male interconnecting means having thedimensions of the male interconnecting means 22. Specifically, therecesses 38 are sized to receive projections having the dimensions ofprojections 26 and grooves 42 are sized to receive bridges having thedimensions of bridges 30.

The insulation panel 10 shown in FIG. 1 has been cut into a firstportion 50 and a second portion 54.

FIG. 2A shows insulated concrete formwork 58 incorporating the firstportion 50 of the insulation panel 10 and the second portion 54 of theinsulation panel 10. The second portion 54 of the insulation panel 10has been flipped and positioned above the first portion 50 in a mannerto connect with the first portion 50 of the insulation panel 10.

A block 60 is also shown in FIG. 2A. The block 60 is rectangularlyshaped and formed from a malleable substance such as polystyrene or thelike. The block 60 has a bottom surface 64 and a top surface 68 opposingthe bottom surface 64. The top surface 68 and the bottom surface 64 ofthe block 60 have like interconnecting means.

The like interconnecting means of the block 60 shown in FIG. 2A arefemale interconnecting means 72. The female interconnecting means 72extend along the entire length of the top surface 68 and the bottomsurface 64 of the block 60. The female interconnecting means 72 on thetop surface 68 and the bottom surface 64 are each aligned into two rows.The female interconnecting means 72 include recesses 76 and grooves 80.The grooves 80 each connect adjacent recesses 76. The femaleinterconnecting means 72 are sized so that they may receive the maleinterconnecting means 22 of the insulation panel 10. Specifically, therecesses 76 may receive the projections 26 and the grooves 80 mayreceive the bridges 30.

FIG. 2B shows insulated concrete formwork 90 incorporating the firstportion 50 of the insulation panel 10 and the second portion 54 of theinsulation panel 10. The second portion 54 of the insulation panel 10has been flipped and positioned below the first portion 50 in a mannerto connect with the first portion 50 of the insulation panel 10.

A block 94 is also shown in FIG. 2 b. The block 94 is rectangularlyshaped and formed from a malleable substance such as polystyrene or thelike. The block 94 has a bottom surface 96 and a top surface 98 opposingthe bottom surface 96. The top surface 98 and the bottom surface 96 ofthe block 94 have like interconnecting means.

The like interconnecting means of the block 94 shown in FIG. 2B are maleinterconnecting means 100. The male interconnecting means 100 extendalong the entire length of the top surface 98 and the bottom surface 96of the block 94. The male interconnecting means 100 on the top surface98 and the bottom surface 96 are each aligned into two rows. The maleinterconnecting means 100 include projections 104 and bridges 106. Thebridges 106 each connect adjacent projections 104. The maleinterconnecting means 100 are sized so that they may be received by thefemale interconnecting means 34 of the insulation panel 10.Specifically, the projections 104 may be received by the recesses 38 ofthe insulation panel 10 and the bridges 106 may be received by thegrooves 42 of the insulation panel 10.

Insulated concrete formwork 160 is shown in FIG. 3. The insulatedconcrete formwork 160 has been partially cut away to show the componentsof the insulated concrete formwork 160. The insulated concrete formwork160 incorporates four insulation panels 164, 168, 172 and 176.Insulation panels 164 and 172 have been flipped such that theirrespective bottom surfaces 180 and 184 are facing upward.

The insulated concrete formwork 160 shown in FIG. 3 also incorporatestwo blocks 94. A block 94 connects insulation panels 164 and 168 and ablock 94 connects insulation panels 172 and 176.

Each of the insulation panels 164, 168, 172 and 176 has a series ofslots 196. Each of the blocks 94 also have a series of slots 200. Theslots 196 of the insulation panels 164, 168, 172 and 176 receive webs204 of the insulated concrete formwork 160.

The insulated concrete formwork 160 also incorporates a continuousstirrup 208 for each set of two insulation panels and two reinforcingmembers 212 and 216 for each set of insulation panels. An adhesivesubstance 220 is put between the insulation panels 164, 168, 172 and 176and the blocks 188 and 192. The adhesive substance 220 is a substancethat may be poured and that sets upon drawing, such as concrete, groutor the like.

In operation, the block is used when it becomes necessary to connectsurfaces of insulation panels and the surfaces have like interconnectingmeans. This may occur when a slanted gable (not shown) is encounteredduring the construction of insulated concrete formwork. As seen in FIG.1, the insulation panel 10 is cut at an angle to match the slope of thegable to form first portion 50 and second portion 54. If the secondportion 54 of the insulation panel 10 is to be set flush with the gable,it must be flipped over, as seen in FIGS. 2A and 2B. To then attach thesecond portion of the insulation panel with the first portion 50 of theinsulation panel 10, the block 60 or the block 94 is used. Thereafter,it may be necessary to cut the block 60 or the block 94 at an anglematching the slope of the gable such that the block may be laid flushwith the gable. Further insulation panels or a portion of a furtherinsulation panel may also be connected to the block 60 or block 94.

Numerous modifications may be made to the embodiments described abovewithout departing from the scope of the invention, which is defined bythe claims.

1. A device for connecting insulation panels of insulated concreteformwork, each panel having opposing edges and male interconnectingmeans on a first said edge and female interconnecting means on a secondsaid edge, comprising: a block with opposing edges wherein each opposingedge of the block has only male interconnecting means and said maleinterconnecting means can mate with said female interconnecting means onsaid second edge of each of said panels.
 2. The device of claim 1wherein the block is rectangular.
 3. The device of claim 1 wherein theinterconnecting means extend along the entire length of each opposingedge of the block.
 4. The device of claim 1 wherein two rows ofinterconnecting means are aligned on each edge of the block.
 5. Thedevice of claim 1 wherein the device is formed from polystyrene.
 6. Adevice for connecting insulation panels of insulated concrete formwork,each panel having opposing edges and male interconnecting means on afirst said edge and female interconnecting means on a second said edge,comprising: a block with opposing edges wherein each opposing edge ofthe block has only female interconnecting means and said femaleinterconnecting means can mate with said male interconnecting means onsaid first edge of each of said panels.
 7. The device of claim 6 whereinthe block is rectangular.
 8. The device of claim 6 wherein theinterconnecting means extend along the entire length of each opposingedge of the block.
 9. The device of claim 6 wherein two rows ofinterconnecting means are aligned on each edge of the block.
 10. Thedevice of claim 6 wherein the device is formed from polystyrene.
 11. Asystem for insulating concrete formwork, comprising: a plurality ofinsulation panels wherein each panel has opposing edges and maleinterconnecting means on a first said edge and female interconnectingmeans on a second said edge; and at least one block connecting two ofsaid insulation panels wherein each opposing edge of said block has onlymale interconnecting means that can mate with said femaleinterconnecting means on said second edge of each of said panels.
 12. Asystem for insulating concrete formwork, comprising: a plurality ofinsulation panels wherein each panel has opposing edges and maleinterconnecting means on a first said edge and female interconnectingmeans on a second said edge; and at least one block connecting two ofsaid insulation panels wherein each opposing edge of said block has onlyfemale interconnecting means that can mate with said maleinterconnecting means on said first edge of each of said panels.